Composite tubing product and apparatus for manufacturing the same



m 7, 1970 R; A MATTHEWS ET AL 3,519,518

UOMPOSl'l'i'Z TUBING PRODUCT AND APPARATUS PUh MANUFACTURING THE SAMl.

3 bhuvts-k3lurut l Original Fllud July 7, .1900

INVENTORS RICHARD A. MATTHEWS BY HANS A..JOHANSEN w 77 V /JMW ATTORNEYS3,519,518 COMPOSITE TUBING PRODUCT AND APPARATUS FOR July 7, 1970 R. A.MATTHEWS ET MANUFACTURING THE SAME Original Filed July 7. 1966 3Sheets-Sheet INVENTORS RICHARD A. BY HANS A. JOHANSEN 17 7L4 :M

MATTHEWS ATTORNEYS July 7, 1970 R. A. MATTHEWS AL 3,519,518

COMPOSITE TUBING PRODUCT AND APPARATUS FOR MANUFACTURING THE SAME,Original Filed July 7, 1966 S-S'neets-Sheet INVENTORS RICHARD A.mw'ruzws BY HANS A. aoumseu an 7 a; M

ATTORNEYS United States Patent O 3,519,518 COMPOSITE TUBING PRODUCT ANDAPPARATUS FOR MANUFACTURING THE SAME Richard A. Matthews, Chagrin Falls,and Hans A. Johansen, Mantua, Ohio, assignors to Samuel Moore andCompany, Mantua, Ohio, a corporation of Ohio Application July 7, 1966,Ser. No. 563,512, now Patent No. 3,400,737, dated Sept. 10, 1968, whichis a continuation-impart of application Ser. No. 250,390, Jan. 9, 1963,now Patent No. 3,269,422. Divided and this application May 9, 1968, Ser.No. 728,000

Int. Cl. B65h 81/00 US. Cl. 156392 Claims ABSTRACT OF THE DISCLOSURE Anapparatus system and method for continuously producing a deformable,composite tubing product including a pay-off device for a sampling lineand pay-off device for a heating line with a conveyance system formoving the lines in engaged heat transfer relation along their length.An applicator mechanism is disposed for applying a flexible,thermo-barrier layer around the lines and an extruding mechanism isdisposed for applying an outer flexible polymeric sheath around thethermo-barrier layer.

This is a division of the copending application to Richard A. Matthewsand Hans A. Johansen, Ser. No. 563,512, filed July 7, 1966, now PatentNo. 3,400,737 which is a continuation-in-part of application Ser. No.250,390, filed Jan. 9, 1963, now Pat. No. 3,269,422 to Richard A.Matthews and Hans A. Johansen.

BACKGROUND OF THE INVENTION This type of a tubing finds its principaluse in the chemical processing and petroleum refining industries, and isused, for example, for conveying a sample of fluid from a process line,or a reaction vessel, to an automatic instrument, such as a continuoussampling instrument for example a chromatograph or infrared spectograph.Samples of the fluid taken under these conditions gener ally must bemaintained at a relatively elevated temperature, because the viscosityof the fluid must be kept as low as possible, and moreover in case of agas sample being transmitted, the gaseous sample must not be permittedto condense.

At the present time these sampling lines are oftentimes made up at thesite, by supporting a steam carrying copper pipe from a point ofsampling, to the instrumentation that is adapted to receive the sample,and then utilizing a sample tube of stainless steel for transmitting thesample, and bending the stainless steel tube in appropriate places forclamping to the supporting heating tube. The overall structure is thengenerally coated with a cement such as for instance Thermon and may bewrapped with insulation, such as cork or the magnesia-type, formaintaining the temperature of the sampling tube. Oftentimes, the entirestructure is then wrapped with a metal tape, or covered with pitch, inorder to protect it from weather conditions.

This type of structure, is extremely expensive and difficult to lay out,and moreover in the event of any difiiculties with the samplingstructure, it is almost impossible to repair, and therefore is generallycompletely torn out, and completely replaced in the event of any such m3,519,518 Ice Patented-July 7, 1970 trouble. Also because of the custommade construction, the heat conductivity from one end of the samplingstructure to the other may not be uniform, and often results in coldspots. Accordingly, such custom made sampling structure has not beencompletely satisfactory, so far as industry is concerned.

In the aforementioned application Ser. No. 250,390 there is disclosed acomposite tubing product that is more satisfactory as compared to suchheretofore known arrangements and which generally comprises a metallicheating line and a metallic sampling line disposed in engaged relation,and about which is disposed an insulating layer covered with a sheath offlexible polymeric material. In such tubing product the sampling line iscomprised of a metallic material, such as for instance stainless steel.It has been found, however, that metallic materials, such as stainlesssteel, are not entirely satisfactory in certain sampling lineapplications, such as in sampling flue gases, where the samplingmaterial contains a large amount of chlorides and/or other corrosivematerials damaging to stainless steel. Though other corrosion resistantmetal alloys may be available for such purposes, their significantlyincreased cost renders use thereof impractical in many applications.

Another important difliculty with the all metal construction (i.e.,heating line and sampling line) resides in the heat moderating anddistributing characteristic between the heating line and the samplingline. Such arrangements result in a substantial reduction in modularcontrol of heat transfer with consequent formation of random hot spotsalong the length of the sampling line when handling heat sensitivematerials, particularly at elevated temperatures.

A further difiiculty with such all metal constructions is that they arenot completely satisfactory in certain applications in producing optimumbundle flexibility, particularly when a plurality of sampling lines areemployed. In addition, it has been found, as a practical matter, thatcertain forms of metal alloys, such as of stainless steel and/ or otherexotic metal alloys, which may be employed for sampling line purposesare available only in relatively limited lengths and/or in certain sizeswhich renders their use unsatisfactory in many applications.

SUMMARY OF THE INVENTION The present invention, therefore, constitutesan improvement over that which is embodied in the aforementionedapplication Ser. No. 250,390 and contemplates the provision of anapparatus system and method for producing a composite tubing productwhich comprises one or more metallic heating lines and one or morepolymeric sampling lines disposed in engaged heat transfer relation withone another about which may be disposed a heat insulating and/ orconductive media, and all of which may be covered with a sheath ofpolymeric material to provide a unitary sampling structure.

Accordingly, an object of the present invention is to provide animproved construction for an apparatus system and method for producing acomposite tubing product adapted for use in conveying fluids, such asfor sam pling purposes, which provides a more uniform, modular controlof heat transfer between the heating line and the sampling line; whichincorporates one or more flexible, polymeric sampling lines havingimproved corrosion resistance; which provides an improved bundleflexibility,

particularly when a plurality of sampling lines are employed; which isquick and easy to install at the work site; which is of a uniformconstruction throughout its length for producing consistent and accuratesampling results; and which can be eflficiently mass produced withminimum expense.

Other objects and advantages of the invention will be apparent from thefollowing description taken in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a partially cut away elevational view of a composite tubingproduct produced in accordance with the instant invention; a

FIG. 2 is a transverse cross-sectional view taken generally along theplane of line 22 of FIG. 1 looking in the direction of the arrows;

FIG. 3 is a sectional view generally similar to that of FIG. 2, butillustrating a modification of the FIGS. 1 and 2 arrangement;

FIG. 4 is a partially cut away elevational view of a modified form ofcomposite tubing product as compared to that of FIGS. 1, 2 and 3;

FIG. 5 is a transverse sectional view taken generally along the plane ofline 55 of FIG. 4, looking in the direction of the arrows;

FIG. 6 is a partially cut away elevational view illustrating anotherembodiment of composite tubing product;

FIG. 7 is a transverse sectional view taken generally along the plane ofline 7-7 of FIG. 6, looking in the direction of the arrows;

FIG. 8 is a partially cutaway elevational view of another embodiment ofthe composite tubing product of the invention;

FIG. 9 is a partially cutaway elevational view of a further modificationof composite tubing product made in accordance with the invention;

FIG. 10 is a transverse sectional view taken generally along the planeof line 10-10' of FIG. 9, looking in the direction of the arrows;

FIG. 11 is a more or less diagrammatic, top plan view of apparatusdisposed in an organized system, for producing the composite tubingproducts illustrated for instance in FIGS. 1 to 5 inclusive;

FIGS. 12 and 13 are top plan generally diagrammatic views of apparatusdisposed in an organized system for producing the embodiment of thecomposite tubing illustrated for instance in FIG. 8; and

FIG. 14 is a top plan, generally diagrammatic illustration of apparatusdisposed in an organized system for producing the tubing embodimentillustrated for instance in FIGS. 6 and 7 of the drawings, and moreparticularly a tubing embodying an expanded foam type of thermo barrier.

Referring now to the drawings, and more particularly to FIGS. 1 and 2thereof, there is shown a piece of composite tubing T comprising asampling or control line 10 and a heating line 12 running parallel tothe control line 10, and disposed in abutting contact therewith. Thesampling line 10 is preferably made from a polymeric material, and theheating line 12 is preferably made of a good heat transmitting,anticorrosion metallic material, such as for instance copper. Theheating line 12 is adapted to carry, for instance steam. Encompassingthe heating and sampling lines may be a layer 14 of filter material togive a generally cylindrical or uninterrupted configuration to thebundle of juxtaposed lines 10 and 12.

In accordance with the invention, the preferred materials for use in thepolymeric sampling line 10 are the fluorinated hydrocarbons, such aspolytetrafluoroethylene known as Teflon PTFE or fluorinated ethylenepropylene known as Teflon FEP. The PTFE material has a highertemperature resistance and relatively better chemical resistance and is,therefore, preferred. Other materials which are suitable are the Kel-Fresins produced by Minnesota Mining & Manufacturing. Materials which maybe suitable for some applications include polymers, such as the nylons,polyacetates and high density polyethylenes.

The layer 14 of filler material may be formed of fibrous material, suchas for instance, jute, or other filamentary material, and may besomewhat heat insulating. The lines 10 and 12 and filler material 14 arethen wrapped with a good thermo barrier 16, such as for instance alaminated Dacron-asbestos tape known as Mylar and having good heatinsulating characteristics. Dacron, a trademark, is a syntheticpolyester fiber produced by the condensation of terephthalic acid andethylene glycol. Mylar, a trademark, is a polyethyleneterephthalatepolyester film of tough, strong characteristics. This wrap is preferablyapplied in the overlapping spiral fashion illustrated in FIG. 1, andthen the wrapping 16 is covered with an outer sheath or jacket 20 offlexible plastic material, to add to the corrosion resistance of thecomposite tubing and prevent weathering of the materials making up thecomposite tubing. This outer jacket may be formed of any suitableflexible plastic material, such as for instance the polyvinyl chlorides,polyethylenes, polyurethenes, neoprenes, or fluorocarbons (e.g.,Teflon).

FIG. 3 illustrates a form of composite sampling tubing similar to thatof FIGS. 1 and 2 except that there has been provided a plurality, andmore particularly three, heating tubes or lines 12 disposedsymmetrically and generally parallel about the sampling tube 10 and inintimate contact therewith, for increased and more uniform heating ofthe sampling tube. It will be understood that while only one samplingline has been illustrated, that the composite tubing could also includea plurality of such sampling lines.

Referring now to FIGS. 4 and 5, there is shown a composite samplingtubing comprising a sampling tube 22 and a generally parallel juxtaposedheating tube 24. In this form, a plurality of preferably good heattransmitting elongated elements, such as copper wires or rods 26, aredisposed in the valleys defined between the juxtaposed tubes 22 and 24,for generally rounding out the configuration of the line bundle 22 and24 into a generally oval-shaped, and then the heat insulating wrapmaterial 16 or thermo barrier is wound around such configuration, and inthe same general manner as aforedescribed in connection with FIGS. 1 to3. Then, the whole package is jacketed in the outer plastic sheathmaterial 20.

In accordance with the invention and referring now to FIG. 11, there isdiagrammatically illustrated apparatus set up in an organized system forproducing the tubing shown for instance in FIGS. 1 to 5 of the drawingsand which constitutes the divisible subject matter of the aforementionedapplication Ser. No. 250,390. Such apparatus may comprise a reel 28 ofthe sampling tubing 10 or 22 and a reel 30 of the heating tubing 12 or24. It will be understood, of course, that if more heating line runs areutilized, in the composite sampling tubing than one, and as for instancethe three runs illustrated in FIG. 3, then more reels of the heatingtubing disposed about the reel of the sampling tubing will be required.

The heating and sampling lines may be moved through a straightener 32which may consist merely of a powered rotatable grooved cylindricalmember, for moving and straightening the tubing from the reels, and thenthe tubing disposed in juxtaposed relation may be moved through aconventional filler applying mechanism 32 for applying the flexiblefiller material 14 to the tubing. This mechanism 34 may include meansfor chopping up fibers, for instance if the fibers are comprised offiberglass or the like, and for mixing such fibers with a suitableadhesive material as is conventionally known in the fiber art, and thenapplying the fibrous materials as by blowing of laying it down in asuitable manner about the associated sampling and heating lines 10 and12 to produce the uninterrupted surface configuration. The fiber coatedtubing may then be passed through a conventional taping mechanism 36 forapplying the thermo barrier 16 thereto, and at which time theasbestos-Dacron tape is wound about in overlapping relation the fillerlayer 14. The wrapped tubing may then be moved on the conventionalroller conveyor 38 through a conventional extruding mechanism 40,including cross head 40a, where the hot plastic material is applied toform the flexible outer sheath 20 of the composite tubing. There mayalso be provided in conjunction with mechanism 40, a conventional vacuumunit 44, for sizing the outer sheath and maintaining a predeterminedthickness thereof on the thermo barrier layer 16. From the cross head40a of the extruder, the hot tubing may move first into a preliminarycooling tank 46 filled with, for instance, water, for setting theplastic material forming the outer sheath 20, and then a hauloffmechanism 46a of any suitable type and as for instance the well knowncatapillar type, may be utilized to move the tubing into a further maincooling tank 46b for cooling and curing of the tubing adequately forwinding it upon reel mechanism 48 where it is ready for use.-

If the composite tubing is of the type illustrated for instance in FIGS.4 and 5, and not having the fibrous filler layer 14, then station 34will apply the filler wires or rods 26, which wires may be mounted uponreels, and moved with or layed down in the valleys between the samplingand the heating lines to give a more uninterrupted surface to the linebundle as well as more uniform heat transfer.

Referring now to FIGS. 6 and 7, there is illustrated a compositesampling tubing wherein instead of having the thermo barrier layerformed by a wrap of asbestos and Dacron tape, the thermo barrier 50 isprovided by a cured expanded foam material, such as for instance curedpolyurethane foam, which is of high heat insulating character. In otherrespects, this composite tubing is generally similar to the firstdescribed embodiments.

The polyurethane foam could be performed, having apertures runningtherethrough for receiving therein in cured condition, the sampling lineand the heating line 12, or the polyurethane foam material may be mixedup and applied in the tubular liquid or gel form before the foam sets.

Referring to FIG. 14, there is illustrated diagrammatically, apparatusset up in an organized system, for providing the foamed thermo barrierlayer 50 of FIGS. 6 and 7 which also constitutes the divisible subjectof the aforementioned application Ser. No. 250,390. The sampling andheating lines 10 and 12 are moved from a payoff station 52 through thestraightener 32, to station 54 where the expanded foam thermo barrier 50may be applied. Such station may include holding tanks 56, 56a forrespectively the prepolymer and the catalyst or chain extender, and amixing head 58 together with a control panel and metering pump 60, allconventional mechanism utilized in the production of expandedpolyurethane foam. The foam is applied to the juxtaposed sampling andheating lines in head 58 after mixing and foaming of the prepolymer andcatalyst, and the foam coated tubing may pass through a drying mechanism62 for positively setting and curing the foam, on the sampling andheating lines. Thereupon, the foam coated lines are passed through theaforedescribed extruding mechanism 40 which applies the external plasticsheath to the composite tubing, and then such tubing may be passedthrough a conventional cooling tank to adequately cool the outer sheath,for winding upon a coiler 48 for shipment or storage. This extrudingmechanism does not embody a preliminary cooling tank as that identifiedby numeral 46 in the FIG. 11 arrangement, since the sheath material maybe adequately set upon extrusion at head 40a, for coaction with haul-off46a.

FIG. 8 illustrates a modification of the invention wherein the samplingline 10 is preferably wound in spiral form about the heating line 12b inintimate contact therewith, instead of having the sampling line runningparallel or linearly. Such an arrangement will give a generally moreuniform degree of heating of the sampling line. In other respects theFIG. 8 is generally similar to that aforediscussed in connection withFIGS. 1 and 2.

Referring to FIGS. 12 and 13, there is illustrated apparatus for formingthe spiral Wound sampling arrangement illustrated in FIG. 8, whichfurther constitutes the divisible subject matter of aforementionedapplication Ser. No. 250,390, and wherein the coil 30 of heating line12a is fed through a conventional cabling machine 66 having a reel 28 ofsampling line which spirals the sampling line 10 about the heating lineand then passes the material to the filler layer applying mechanism 34and the taping machine 36 similarly as in the first describedembodiment. The tubing may then be wound upon a reel 68 and then thereel 68 may be transferred to pay-off station 70 where the tubing may befed to a conveyor 72 and then through extrusion mechanism 40 in asimilar manner as aforedescribed for the first embodiment. While themechanism or apparatus for producing the spirally wound sampling linetype of composite tubing has been shown in two distinct steps, it willbe understood that such apparatus could be disposed in an alignedcondition for the continuous production of tubing. Furthermore and asdisclosed in the aforementioned application Ser. No. 250,390, it is tobe understood that when the apparatus is employed for producing thespirally wound metal sampling line construction, a coil of metalsampling line would be fed through the cabling machine 66 having a reelof metal heating line which spirals the heating line about the samplingline rather than vice versa, as in the present application.

FIGS. 9 and 10 illustrate a modified form of the spirally wound samplingline type of tubing, using the thermo barrier layer 50 aforedescribed inconnection with FIGS. 6 and 7; also there has been provided a pluralityof sampling lines 10 spirally wrapped around the heating line 12b.

The composite tubing of the invention enjoys greatly reduced costs ofinstallation, as compared to the custom made structures heretofore used,is of considerably less bulk and of a smaller cross section and lighterweight per foot, as compared to such prior arrangements, and a tubingwhich gives much more accurate and uniform results from samples takenthereby.

What is claimed is:

1. In an apparatus system for producing a deformable, composite tubingproduct for use in sampling fluids, said system comprising pay-off meansfor a sampling line, pay-off means for a heating line, means disposedfor moving said lines in engaged heat transferring relation throughouttheir length, means for applying a flexible thermo-barrier layer inencompassing relation with respect to said lines, and means for applyingan outer flexible polymeric sheath to said thermo-barrier layer, andmeans for moving the product in a direction parallel to its lengththrough the system.

2. In an apparatus system in accordance with claim 1, including a meansfor applying a filter material to said lines prior to application ofsaid thermo-barrier layer.

3. In an apparatus system in accordance with claim 1, including coolingmeans for cooling the product after movement thereof beyond said meansfor applying said polymeric sheath.

4. In an apparatus system in accordance with claim 1, including meansfor applying said sampling line in spiral engaged relation wtih respectto said heating line.

5. In an apparatus system in accordance with claim 1, including astraightener device for moving and straightening the lines from saidpay-off means.

6. In an apparatus system in accordance with claim 2, wherein saidapplying means includes means for blowing the filler material into saidlines.

7. In an apparatus system in accordance with claim 3, wherein saidcooling means includes a first fluid cooling 7 tank for setting thematerial of said outer sheath, and a second fluid coling tank for finalcooling of the tubing.

8. In an apparatus system in accordance with claim 7, including a reelmechanism for storing the cooled tubing in wound relation for use.

9. In an apparatus system in accordance with claim 2, wherein saidapplying means includes reel mechanisms for applying metallic wireelements in the valleys between said lines.

10. In an apparatus system in accordance with claim 1, wherein the meansfor applying said thermo-barrier layer includes a mixing mechanism formetering and blowing polymeric foam material onto said lines.

References Cited UNITED STATES PATENTS BENJAMIN A. BORCHELT, PrimaryExaminer US. Cl. X.R.

